Fabric forming apparatus



May 7. 1969 R. H. MARKS ETAL 3,446,041

FABRIC FORMING APPARATUS Filed Feb. 10. 1966 Sheet of. 4

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FABRIC FORMING APPARATUS Filed Feb. 10. 1966 Sheet 4 of 4 a! 07 o a: 20 v e I I I L I z a/ I d3 (90 a r x T {I 74 I n k /o R r 2:

United States Patent 3,446,041 FABRIC FORMING APPARATUS Ronald H. Marks, Lawrence R. Goodman, Luther E. Stokes, and Roy H. Millard, Dallas, Tex., assignors, by direct and mesne assignments, to American Can Company, New York, N.Y., a corporation of New Jersey Filed Feb. 10, 1966, Ser. No. 526,580 Int. Cl. D04b 15/48 US. Cl. 66-125 3 Claims ABSTRACT OF THE DISCLOSURE An apparatus for producing a knitted fabric including a knitting machine, and a frame for supporting a roll of web material, a cutter to divide the web material into a plurality of elements and means delivering the elements to the knitting machine for knitting into a fabric. This abstract is neither intended to define the invention of the application which, of course, is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.

The present invention relates to an improved apparatus for producing a fabric by supplying elements which are derived from a web material to a weft knitting machine and knitting such elements into a fabric.

Web material has previously been cut into pre-selected widths, treated and fed to a knitting machine to be knit into a knitted fabric. A typical example of apparatus used for this purpose is disclosed in the R. H. Marks Patent No. 3,214,943, issued Nov. 2, 1965.

It has been discovered that the web material may be handled more economically if suitable apparatus is provided to assure uniformity of treatment, the continuity of tension in the web material, the elimination of static electricity in the web material and elements cut therefrom and a continuity of supply of web material for substantially continuous operation. Also, it has been discovered that certain materials are more readily processed into a knitted fabric if they are subjected to a minimum of ten- S1011.

Therefore, an object of the present invention is to provide an economic, compact apparatus having the necessary components to perform the steps of cutting a web of material, treating such material and feeding elements of such material to a knitting machine.

A further object is to provide an apparatus which is readily combined with a circular knitting machine to cut, treat and feed elements to such knitting machine from a source of web material.

Another object is to provide an apparatus to cut, treat and feed elements from a web material to a knitting machine with the speed of such feeding being readily coordinated to the speed of the knitting machine.

Another object is to provide an apparatus for cutting, treating and feeding elements from a source of web material to a knitting machine including the application of a treating liquid and the removal of excess treating liquid prior to the feeding of the elements to the knitting machine.

Still a further object is to provide an apparatus for cutting, treating and feeding elements of a web material to a knitting machine including apparatus to assist in the maintenance of a uniform tension in the strips and for stopping the apparatus and knitting machine in the event one of the elements breaks.

Another object is to provide an apparatus for cutting, treating and feeding elements to a knitting machine which feeds such elements to each knitting station with a minimum of friction.

3,446,041 Patented May 27, 1969 A still further object is to provide a compact unitary assembly having improved arrangement for cutting, treating and feeding elements from a source of web material to a knitting machine which straightens the web material to eliminate wrinkles and eliminates static electricity in the web material before cutting.

The construction design to carry out the invention will be hereinafter described, together with other features thereof.

The invention will be more readily understood from a reading of the following specification and by reference to the accompanying drawings forming a part thereof, wherein an example of the invention is shown, and wherein:

FIGURE 1 is a perspective view of one form of the conversion apparatus of the present invention and schematically illustrates the position of the rotating cylinder knitting machine which it is to feed in dashed lines;

FIGURE 2 is a partial side elevation of the apparatus illustrated in FIGURE 1;

FIGURE 3 is a partial plan view of the apparatus as shown by line 3-3 in FIGURE 2 and illustrates the adjustable means for wiping excess treating liquid from the elements;

FIGURE 4 is a partial side elevation of the opposite side of the apparatus from the side down in FIGURE 2 and particularly illustrating the treating system;

FIGURE 5 is a partial side elevation of the apparatus illustrating the use of the splicing means;

FIGURE 6 is a perspective view of the feeding guides at one station on the knitting machine;

FIGURE 7 is an end view of the means used to align and remove wrinkles from the web material; and

FIGURE 8 is an elevation view of another form of apparatus of the present invention installed on a rotating plate knitting machine.

The application of the process of converting different kinds of Web material, such as paper, vinyls, polyethylene and other similar plastic materials, to a knitted product, has required that specal considerations be given to the apparatus which converts the web material into elements suitable for feeding to a knitting machine.'In the conversion of some plastics, a very accurate control of tension, particularly in feeding to the knitting machine, to maintain a minimum tension is desirableto prevent a slight stretching of the individual elements. Some materials have a static charge of electricity when unwound from a roll. Such static electrical charge may interfere with the successful conversion of the materials to a knitted product and should be eliminated. The treatment of the elements which are to be fed to a knitting machine should be carefully controlled so that the elements are amenable to the knitting and, when knit, form the desired fabric.

In the preferred form of the present invention the apparatus includes a frame structure F, which is designed to support both the feed stock and the components of the apparatus which perform the conversion of the web material from the feed stock, and is also designed to be compact and to deliver the elements produced to the knitting machine at the proper height. The feed stock, which would include at least two rolls designated R-1 and R-2, is supported by means on the frame F, such as the two pairs of arms 10 and suitable bearings 11 secured to the arms 10 to receive the shafts 12 of the two rolls. Thus, the rolls are mounted on the frame and are free to turn as the web material is withdrawn from the rolls. A braking mechanism 13, seen in FIGURE 1, is positioned on each of the shafts 12 to retard the withdrawal of the web material from the roll and thereby provide a resisting force which develops the proper tension in the web material. The direction of travel of the web material as seen in FIGURES 1 and 2 is generally 3 through the conversion apparatus supported on frame F from the right to the left toward the knitting machine K.

The apparatus is designed to draw web material from either of the two rolls R-1 and R2 in order to assure that a substantially continuous supply of web material W is available for the operation of the apparatus. The web material W withdrawn from the roll R-l, as seen in FIGURE 2, is threaded through the splicing means 14. The splicing means 14 illustrated in the figures is suitable for splicing thermoplastic materials. The splicing means includes a pair of arms 14a, a base 14b and the heating element 140 supported by arms 1411 which engages the web material on said base to form a bond between the last portion of web material from one roll and the initial portion of web material from the other roll. This splicing operation is hereinafter more clearly explained in relation to FIGURES 4 and 5.

From the splicing means the web material extends over the idler roller 15 and into proximity with the static eliminator 16. The static eliminator may be any suitable type generally used in the industry by manufacturers of palstic films to eliminate static electricity. Generally, such equipment utilizes a power source and a converter to feed a direct current into a static bar which neutralizes the charge on the film by emitting positive charges. The static eliminator is generally placed within an inch or two of the surface of the film. The elimination of static from the web material will be such as to prevent any tendency of the elements into which the web material is cut from clinging to each other or to portions of-the conversion apparatus. This elimination of static electricity, therefore, facilitates the separation of the elements and also assures uniform treating of the elements in the manner hereinafter explained.

The web material extends from the roller 15 to the power rollers 17 and 18 which provide the power necessary to overcome the resistance offered by the braking mechanism 13 and deliver the web material W over the bow bar 19 to the cutting means 20.

The bow bar '19 functions to straighten the web material, to eliminate creases and folds and to assure that the web material is straight before cutting. The bow bar 19 is mounted on the base 21 which is secured between the side frames of the cutting means 20. As best seen in FIGURE 7, the bow bar 19 is a slightly curved rod which is secured to the base 21 by any suitable means, such as the threaded end portions and the nuts 22. The bow bar extends upwardly slightly above the direct line connection from the power roller 18 to the cutting means to exert an upward force on the web material W which will eliminate creases from the web material and assure a uniform feeding of the web material to the cutting means 20.

The web material W is cut into a plurality of elements having a predetermined width by the cutting means 20. The cutting means 20 may be of any suitable type, such as a cutter as shown, in which spacers are positioned between the cutter blades, and the width of the strips cut may be preselected by preselecting the correct width of spacer. The cutter divides the web material W into elements E of the desired width. The determination of the width of elements E is based upon the end fabric which is to be produced and by the size of the needles needed to produce the desired fabric. If small needles are required to produce the desired fabric, then the width of the elements E is of necessity smaller than those used for the larger needles in order for the elements to be received in the hook of the needles and to be compressed or crushed by the hook and the pulling of the elements through the precedingly formed loop in the fabric.

While the elimination of the static electricity in the web material W before it is cut is helpful, with certain materials, such as thin plastic films, it is also advantageous to provide a second static eliminator 16a positioned in close spaced relationship to the elements E as they are discharged from the cutting means 20. As shown, static eliminator 16a is supported from the frame of the cutting means 20. This static eliminator 16a is similar to static eliminator 16. Either static eliminator or a combination of both static eliminators 16 and 16a may be used to assure that the conversion of the web material W into elements E, the treating of elements E and the knitting of the elements E into a fabric are not hindered by static charges.

After the elements have been formed from the web material, they are next conducted to the treating means. The elements are treated normally by the application of a liquid which renders the elements more suitable for the knitting operation and also may include an additive which is desired in the final fabric produced. Generally, papers require the application of a liquid treating agent which renders them more pliable for the condensing step by the needles and also for the knitting operation itself. Some plastic materials require the application of a treated liquid which functions as a lubricant for the plastic to avoid introducing additional tension in the plastic elements during their passage from the cutter to the knitting machine.

The applying means is part of the treating means illustrated and includes the applicator tank 23 in which liquid to be applied to the elements E is contained, the applicator roller 24 and the wiper 26. The applicator roller 24 is mounted in the applicator tank 23 and is adapted to be rotated in either direction by the motor 25 (or any other drive source). The applicator roller 24 will pick up the treating liquid contained in the tank 23 and supply the elements- E with the treating liquid. The wiper 26 is supported on the tank 23 and adapted to engage the upper side of the roller 24. Generally, the material of wiper 26 which engages the elements is preferred to be a heavy felt which will at least partially absorb the treating liquid and wipe a portion of any excess liquid from the elements E while assuring that the upper side of each of the elements E is provided with the treating liquid. The treating liquid is supplied to the applicator tank 23 from the reservoir 27 by the pump 28 which is powered by the motor 25. Suction line 28a connects pump 28 with the reservoir 27 and discharge line 28b connects from pump 28 to tank 23. It is preferred that the level of liquid in the applicator tank 23 be maintained at approximately the same level at all times, and this may be accomplished by suitable controls (not shown) or manually as desired.

The comb 29 is provided to separate each of the elements E and to deliver them in slight spaced relationship to the treating means T. In this way, application of a uniform amount of treating liquid to each of the elements E is assured.

Also, as a portion of the treating means, suitable means is provided to remove the excess of treating liquid normally applied to the elements E by the applicator roller 24 to assure that the elements are adequately treated. The rotational speed and direction of rotation of the applicator roller 24 may be controlled to deliver more or less treating liquid as desired. The elements passing from the tank 23 are shown to engage the edge of the tank in order to remove some of the excess treating liquid therefrom. Additionally, the elements are further treated by the adjustable combs 30 and 31 to remove the additional excess treating liquid from the elements E. The adjustable scraper combs 30 and 31 are mounted for relative lateral movement immediately above the excess liquid trough 32 and are each suitably slotted to vary their relative position. As the combs are moved farther apart to the dashed positions illustrated in FIGURE 3, additional scraping action will be exerted on the elements E to remove more liquid than would be removed by the position of the combs shown in solid lines in FIGURE 3. This liquid removed by the combs 30 and 31 will drain down the combs into the trough 32 and be conducted back to the reservoir 27 by the drain 33.

The treated elements, thereafter, pass through the spreader comb 34 to the power rollers 35 and 36.

The power rollers 35 and 36 are driven, as hereinafter more fully explained, to provide additional control of the tension of the elements E during their passage from the cutter through the treating means. The flexible tension fingers 37 are secured at their base to the bar 38 which is, in turn, secured to the frame F. The flexible tension fingers 37 are provided with loops in their free end in which one of the elements is to be engaged for each finger.

In operation, the fingers 37 are sufficiently flexible to bend downward :at their free end and provide an upward lift to the elements E to take up any slack in the elements and to assure that each of the elements is under substantially the same tension. The elements pass through the loop at the free end of the fingers 37 and over or through holes in the bar 38 to the individual feeding stations on the knitting machine K. The tension fingers 37 are also adapted to move up against the stop bar 39 whenever the element passing through its free end becomes sufficiently loose to allow the finger 37 to engage the stop bar 39. By suitable circuitry, as shown in FIGURE 2 and in the copending application Ser. No. 413,261, filed Nov. 23, 1964, a circuit may be completed by the finger 37 whenever one of the elements becomes so loose as to allow it to engage the stop bar 39 to shut down the apparatus. This looseness normally only occurs when one of the elements has broken its connection back to the web W. With this stop circuit, the conversion and knitting operations are instantly stopped whenever one of the elements breaks or whenever it becomes sufliciently loose to allow the fingers 37 to engage the stop bar 39.

The individual knitting stations of the knitting machine are provided with special feeding means. Such feeding means is utilized to provide additional control of the tension and feeding of the elements E to the knitting needles of the knitting machine K. This feeding means is illustrated in FIGURE 6. Each feeding station is provided with a standard 40 which supports the needle feed tab 41 at the proper position and level to allow the elements E passing through feed tab 41 to be engaged by the knitting needles 42 in the usual manner. A guide in the form of a wire loop 43 is secured to the standard 40. The elements E extend from the flexible fingers 37 through the guide 43 on the standard 40 adjacent to the station at which they are to be engaged by the needles 42. From the guides the elements extend over the roller 44, which is held by the support 45 at a position between the individual standards 40, and through the feed tab 41 to the needles. This method of feeding, particularly including the roller 44 between the guide 43 and the feed tab guide 41, minimizes the tension in the elements E and will prevent unnecessary breakage and also any tendency of the elements E, when plastic, to elongate.

The power utilized to drive the knitting machine K is also utilized to drive the components of the conversion apparatus. With reference to FIGURES 1 and 2, the motor 46 is connected through the transmission 47 and a suitable belt or chain drive 48 to drive the shaft 49. The shaft 49 is the drive shaft for the knitting machine K. Additionally, shaft 49 is connected through suitable clutch mechanism 50 and gearing 51 and 52 to rotate the shaft 53. Shaft 53 is connected to the variable speed drive mechanism 54 which has a control knob controlling the speed of the pulley 56. This pulley 56- is connected to the drive pulley 57 of the cutter 20 to control the speed of rotation of the cutter 20. Additionally, the power rollers 17, 18 and power rollers 35, 36 are interconnected with the cutter shaft, such connection shown in dotted lines in FIGURES 1 and 4, to synchronize the rotational speed of the power rollers 17, 18, 35 and 36 with the speed of rotation of the cutter 20. The variable speed drive mechanism 54 will also allow the rate at which elements are fed to the knitting machine K to be synchronized with the speed at which such elements are utilized by the knitting machine and incorporated into the fabric being produced.

The control panel 58 is secured to the frame, as shown, and combines switches and indicators for the motor 46, for the motor 25, for the static eliminator 16 and the splicing means 14. If desired, when the applicator roller 24 is driven by a separate drive than the motor 25, controls and indicators for such separate drive will be incorporated into the control panel 58.

With particular reference to FIGURES 4 and 5, the splicing of the end of one roll onto the beginning of the other roll is illustrated. In FIGURE 4, the end of the roll R-2 (roll R-2 being shown in dashed lines) is positioned on the base 14b and the beginning of the other roll R-1 is positioned between the end of the roll R-2 and heating element 14c. With the equipment stopped and the respective ends of the rolls positioned in the splicing means 14 as described, the proper switch is actuated to cause the heating element 14c to heat and, thereby, bond the two ends together. Thereafter, the arm 14a will be raised and any excess material on either side of the bonded area trimmed off and the operation of knitting machine and conversion apparatus continued. In the illustration in FIGURE 5, the end of the roll R-1 is positioned within the splicing means 14, together with the starting end of the roll R-2. The roll R1, which has been exhausted in FIGURE 5, is illustrated in dashed lines. The splicing of the two ends together then proceeds as previously described in relation to FIGURE 4. In this manner, the splicing of one roll to another in plastic materials may be readily done with only a very short interruption in the continuous flow of web material and continuous operation of the knitting machine. When web materials which will not heat-bond to each other are used, a suitable quick-drying adhesive may be used for the splicing operation and the splicing means may be eliminated or used to accelerate the bonding by the adhesive means.

The form of the invention illustrated in FIGURE 8 involves a rotating type of knitting machine in which the feeding stations of the knitting machine rotate while the needles remain in a fixed position. With such a knitting machine the conversion apparatus is mounted on the knitting machine and connected to rotate therewith to preserve the relatioship between the individual elements and the feeding stations for each of such individual elements.

The converting apparatus illustrated in FIGURE 8 is generally the same apparatus as previously described. Such apparatus is schematically illustrated in FIGURE 8 and includes a frame structure S mounted on the rotating table 60 of the knitting machine 61. The frame structure S provides support for the roll terial 63 to be withdrawn therefrom. The power rollers 64 and 65 supply the power for the withdrawing of the web material from the roll 62 and deliver it over the bow bar 66 to the cutting means, cutter 67. The cutter divided the web material into a plurality of elements 68 and the treating maens 69 applies a suitable treating liquid to the individual treating elements 68 before delivering the elements to their power rollers 70 and 71. The tension fingers 72 receive the elements, one element to each tension finger, from power roller 71 to assure proper tension in the elements as they are delivered to the individual feeding stations of the knitting machine.

Power for the apparatus illustrated in FIGURE 8 is provided by the shaft 73 from a suitable source, not shown. The rotation of the shaft 73 will drive the shaft 74 to cause the table 60 to be rotated by the connection between the gear 75 and the rack 76 on the underside of the table 60. The shaft 77 is supported by suitable bearings connected to the rotating table 60 and is provided with a lower pinion 78 which engages in the internal gearing 79 secured to the fixed portion of the knitting machine 61. The shaft 77 is connected through the gearing 80 to the drive shaft 81 for the converting apparatus which is mounted on the frame structure S.

As the table 60 rotates, the entire converting apparatus, including the frame structure S, is rotated. This rotation 62 to allow the web macauses the shaft 77 to rotate because of the engagement of the pinion 78 in the internal gearing 79. The shaft 81 is rotated at the desired speed whereby, through suitable belting, the cutter 67 and the power rollers 64, 65, 70 and 71 are driven at the desired speed. If desired, the connection from the drive shaft 81 to the cutter and power rollers may include a variable speed driven mechanism 82, similar to variable speed drive mechanism 54, to synchronize the speed of the converting apparatus so that the elements 68 are fed to the knitting stations on the knitting machine 61 at the speed with which the elements are converted into the fabric by the knitting machine 61. The knitting machine 61 is provided with suitable apparatus to take up the knitted fabric 83 and wind it onto the roll 84. Such apparatus is commonly used with knitting machines.

Such elements as the static eliminator, the treating means T, the adjustable combs for removing excess treating liquid and the improved guide means at the knitting stations, while not illustrated and described in relation to FIGURE 8, are contemplated to be used on such apparatus where applicable.

From the foregoing it can be seen that the apparatus of the present invention is compact and will economically convert a web material into strips, treat the strips and knit the strips into a fabric. This apparatus has provision for a substantially continuous supply of web material, removes creases and folds from the web material before cutting, eliminates static electricity from the web material or from the elements into which the web material is cut, maintains the desired tension in the web material and the elements to the point at which the elements are knit into a fabric and provides for a uniform treating of the elements.

The foregoing disclosure and discription of the invention are illustrative and explanatory thereof, and various changes in the size, shape and materials, as well as in the details of the illustrated construction, may be made within the scope of the appended claims without departing from the spirit of the invention.

What is claimed is:

1. An apparatus for producing a knitted fabric from a supply of web material, comprising a rotating table weft knitting machine,

a frame structure positioned on the rotating table of said knitting machine for rotation therewith,

means on said frame structure supporting a supply of web material,

cutting means on said frame structure to cut said web material into a plurality of elements having a preselected width,

means delivering web material from said supply to said cutting means,

treating means on said frame structure and including means applying an excess of treating liquid to said plurality of elements, and

means removing the excess of treating liquid to said plurality of elements,

means delivering said treated elements from said treating means to the knitting needles of said knitting machine, and

drive means for said delivering means to deliver said elements to said knitting machine at the rate at which said elements are knitted into the fabric,

said drive means including a toothed surface in the fixed portion of said knitting machine, a drive shaft connected to drive the cutting means and both of said delivering means supported on said frame structure, and

a gear mounted on said drive shaft in engagement with said toothed surface whereby rotation of said frame structure rotates said drive shaft.

2. An apparatus for producing a knitted fabric from a web material, comprising a weft knitting machine,

a frame structure associated with said knitting machine, means on said frame structure supporting two rolls of web mate-rial, cutting means on said frame structure to cut web material longitudinally into plurality of elements having a preselected width, means for delivering web material from said rolls to said cutting means, treating means supported on said frame structure for applying an excess of treating liquid to said plurality of elements and for removing the excess of treating liquid therefrom, means for delivering elements from said cutting means to said treating means, means for delivering said treated elements from said treating means to the knitting needles of said knitting machine, including a plurality of standards, each of said standards positioned on said knitting machine at a knitting station, a plurality of feed tabs, each of said feed tabs supported on a standard and adapted to deliver one of said elements to the knitting needles of the knitting machine, a plurality of supports, each of said supports positioned on said knitting machine between two of said standards, a roller on each of said supports, a guide on each of said standards, each of said elements being delivered to the knittin-g needles through a guide on a standard, over the roller on the adjacent support and through the feed tab on the standard at the knitting station at which the element is to be fed to the knitting needles, drive means for said delivering means and said cutting means to feed elements to the knitting stations of said knitting machine at the rate at which said elements are knitted into a fabric, and a bow bar adapted to engage the web material before it enters said cutting means to eliminate creases and folds and to straighten the web material for delivery to said cutting means.

3. An apparatus for producing a knitted fabric from a web material, comprising a weft knitting machine, a frame structure associated with said knitting machine, means on said frame structure supporting two rolls of web material, cutting means on said frame structure to cut Web material longitudinally into a plurality of elements having a preselected width, means for delivering web material from said rolls to said cutting means, treating means supported on said frame structure for applying an excess of treating liquid to said plurality of elements and for removing the excess of treating liquid therefrom, means for delivering elements from said cutting means to said treating means, means for delivering said treated elements from said treating means to the knitting needles of said knitting machine, including a plurality of standards, each of said standards positioned on said knitting machine at a knitting station, a plurality of feed tabs, each of said feed tabs supported on a standard and adapted to deliver one of said elemnts to the knitting needles of the knitting machine, a plurality of supports, each of said supports positioned on said knitting machine between two of said standards, a roller on each of said supports, a guide on each of said standards,

each of said elements being delivered to the knitting needles through a guide on a standard, over the roller on the adjacent support and through the feed tab on the standard at the knitting station at which the element is to be fed to the knitting needles,

drive meansv for said delivering means and said cutting means to feed elements to the knitting stations of said knitting machine at the rate at which said elements are knitted into a fabric, and

a base plate supported on said frame structures at a position between said rolls and said cutting means,

a heating element, and

means pivotally mounting said heating element to said frame structures at a position above said said base plate,

said web of material from said rolls being delivered to said cutting means by said delivering means between said base plate and said heating element whereby the trailing end of web material from one roll is bonded to the leading edge from the other r011 by heating said heating element with overlapped portions of said web materials between said heating element and said base plate.

References Cited UNITED STATES PATENTS 9/1926 Voegeli 26-54 X 1/1932 Berger 118-124 11/1935 Hejduk 118-124 11/1936 Jones et a1. 242-585 X 6/1939 Howard 118-124 X 1 1/ 1942 Morrison. 9/ 1950 Crawford. 1/1962 Fried 66-125 5/1964 Gourley 57-32 11/1965 Marks 66-125 2/ 1966 Sherman 242-58.1 X 7/1967 Ma-rks 66-125 3/ 1967 Warthen 66-125 8/1967 Mirsky 66-125 X FOREIGN PATENTS 7/1911 France. 10/ 1964 USSR.

MERVIN STEIN, Primary Examiner U.S. Cl. X.R. 

